Flat Cable Extrusion Lines (100+50)

The Flat Cable Extrusion Line, configured with a 100mm primary extruder and a 50mm secondary extruder in a tandem co-extrusion arrangement, is purpose-designed for the production of elevator traveling cables and other flat cable constructions where profile geometry, dimensional stability, and material flexibility are the defining production challenges. Elevator flat cables operate in a uniquely demanding mechanical environment — they undergo continuous flexing through tens of millions of cycles over a cable service life, combined with lateral loads, torsional forces, and the environmental exposure inherent in elevator shaft installations. The TPU and other applicable materials used in these cables must be extruded with precise thickness uniformity across the entire flat profile width, and the bond between insulation layers and the outer sheath must be robust enough to withstand the mechanical fatigue of continuous travel applications without delamination or cracking. The tandem extruder configuration allows the insulation and sheath layers to be applied in a single pass, with the 100mm main extruder handling the primary insulation volume and the 50mm extruder providing controlled co-extrusion of the outer sheath layer or a secondary material. This approach eliminates the thermal and dimensional inconsistencies that can arise when insulation and jacketing are applied in separate production passes, while also improving layer adhesion through the combined heat state of the two layers at the point of fusion. The flat die and cross-head are precision-machined to maintain consistent flow distribution across the full profile width, preventing edge thinning or center thickening that would create localized weak points in the finished cable. Downstream cooling and calibration systems are designed specifically for flat cable geometry, maintaining profile shape and dimensional accuracy through the transition from molten to set state. This extrusion line is the appropriate production solution for manufacturers supplying elevator OEMs, moving walkway system integrators, and other clients where flat traveling cable performance is a safety-critical specification.